Mushroom-Shaped Interlocking Connectors for Floor Tiles
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Solution Overview
Problem
Existing interlocking modular tiles often experience binding issues during installation, leading to poor fitment and uneven surfaces due to exact alignment requirements, which can result in an unsafe and unfitted floor.
Innovation Solution
The use of mushroom-shaped connectors with varying radii and angles allows for relative freedom during installation, providing improved alignment and guidance, enabling tiles to interlock seamlessly without exact alignment, while maintaining structural integrity and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional interlocking connectors are used with exact alignment requirements, then the tiles can interlock tightly, but the installation becomes difficult and binding occurs during installation
Solution Approach 1:
The connector features a mushroom-shaped cap with a curved top surface and rounded edges, replacing traditional sharp-cornered geometric shapes. This curvature allows the connectors to glide past each other during installation without binding, while still achieving tight interlocking when properly positioned
Solution Approach 2:
The connector design incorporates varying radii of curvature along its length, with the top portion having a larger radius than the base portion. This gradual parameter change allows for easier insertion and alignment during installation while maintaining secure interlocking at the connection point
2Stability of the object's composition
If connectors are designed for precise interlocking, then the floor surface becomes stable, but slight variations cause grinding and binding during installation
Solution Approach 1:
The mushroom-shaped cap with its curved surfaces provides a tolerance buffer for manufacturing variations. The rounded geometry allows connectors with slight dimensional variations to still mate properly without grinding or binding, reducing the need for extremely tight manufacturing tolerances
Solution Approach 2:
The connector design features an asymmetric mushroom shape with different radii at different locations. This asymmetry creates a guided insertion path that naturally aligns connectors during installation, compensating for variations in manufacturing precision
3Device complexity
If traditional connectors are used, then the structure is simple, but the tiles may become disconnected and the surface becomes uneven and unsafe
Solution Approach 1:
The mushroom-shaped cap design provides a larger surface area for contact and distribution of loads compared to traditional point or edge connectors. The curved geometry helps distribute stresses more evenly, preventing disconnection and maintaining a smooth, safe floor surface
Solution Approach 2:
The stem portion of the connector is designed to guide the cap into proper alignment with the receiving tile before the actual interlocking occurs. This preliminary guidance action ensures that the connectors engage correctly, preventing misalignment and potential disconnection
Data Source
AI summary
An interlocking tile system comprises tiles that has a body, interlocking cap structure with a first surface and a second surface; a first curved portion connecting the first surface with a radius of R1 to the second engaging surface with a radius of R2, wherein R1>R2; and a stem supporting the cap structure. The cap is a mushroom-like shape. Such configuration of the connector aids in installation by lessening instances of binding and align and guide the caps into their corresponding receiving areas. The tiles are preferably square, and are connected along all four sides.